INTRODUCTION TO

MANUFACTURING
PROCESSES
 1 What is Manufacturing?

CONTENTS 2 Materials in Manufacturing

3 Manufacturing Process

4 Production System
 PART 1

WHAT IS MANUFACTURING?
 MANUFACTURING
The word manufacture is derived from two Latin words: manus (hand) and factus (make); the
combination means made by hand.
As a field of study in the modern context, manufacturing can be defined two ways, one technologic and the other
economic.
Technologically, manufacturing is the application of physical and chemical processes to alter the geometry,
properties, and/or appearance of a given starting material to make parts or products; manufacturing also includes
assembly of multiple parts to make products.

Economically, manufacturing is the transformation of materials into items of greater value by means of one or
more processing and/or assembly operations.
Manufacturing
Technological
The processes to accomplish manufacturing
involve a combination of machinery, tools, power,
and labor in a sequence of operation. Each
operation brings the material closer to the desired
final state.
Economical
Manufacturing adds value to the material by
changing its shape or properties, or by
combining it with other materials that have
been similarly altered. The material has been
made more valuable through the manufacturing
operations performed on it.
Manufacturing

Manufacturing Manufacturing
Processes Processes

Manufacturing
Processes

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 MANUFACTURING
INDUSTRIES
Industry consists of enterprises and organizations that produce goods and/or provide services. Industries can be
classified as primary, secondary, or tertiary.

Primary industries cultivate and exploit natural resources, such as agriculture and mining. .

Secondary industries take the outputs of the primary industries and convert them into consumer and capital goods.
Manufacturing is the principal activity in this category, but construction and powerutilities are also included.

Tertiary industries constitute the service sector of the economy.

⮚ Specific Industries in the Primary, Secondary, and Tertiary Categories

Primary Secondary Tertiary

 MANUFACTURED PRODUCTS
Final products made by the manufacturing industries can be divided into two major classes: consumer goods and
capital goods.

Consumer goods are products purchased directly by consumers, such as cars, smart phones, TVs, tires, and tennis rackets.

Capital goods are those purchased by companies to produce goods and/or provide services. Examples of capital goods include
aircraft, computers, communication equipment, medical apparatus, trucks and buses, railroad locomotives, machine tools, and
construction equipment. Most of these capital goods are purchased by the service industries.
 PRODUCTION QUANTITY AND
PRODUCT VARIETY
Production quantity refers to the number of units produced annually of a particular product type.
Annual production quantities can be classified into three ranges:
(1) low production, quantities in the range 1 to 100 units per year;
(2) medium production, from 100 to 10,000 units annually; and
(3) high production, 10,000 to millions of units.

Product variety refers to different product designs or types that are produced in the plant. Different products have
different shapes and sizes; they perform different functions; they are intended for different markets; some have
more components than others; and so forth.
Quantity VS Variety

There is an inverse correlation between product variety and production quantity in terms of factory operations. If
a factory’s product variety is high, then its production quantity is likely to be low; but if production quantity is
high, then product variety will be low.

Relationship Between Product Variety and Production Quantity in

Product Manufacturing
 MANUFACTURING CAPABILTY
A manufacturing plant consists of a set of processes and systems (and people, of course) designed to transform a
certain limited range of materials into products of increased value.
The three building blocks—materials, processes, and systems—constitute the subject of modern manufacturing and
there is a strong interdependence among these factors.
A company engaged in manufacturing cannot do everything. It must do only certain things, and it must do those
things well.
Manufacturing capability refers to the scope of technical and physical capabilities and limitations of a
manufacturing company and each of its plants.
Manufacturing capability has three dimensions:
(1) technological processing capability,
(2) physical size and weight of product, and
(3) production capacity.
 PART 2

MATERIALS IN MANUFACTURING
Most engineering materials can be classified into one of three basic categories:
(1) metals,
(2) ceramics, and
(3) polymers.

Their chemistries are different, their mechanical and physical properties are different, and these
differences affect the manufacturing processes that can be used to produce products from them.
In addition to the three basic categories, there are
(4) composites - nonhomogeneous mixtures of the other three basic types rather than a unique
category.
Materials
Classification of Engineering Materials
 META
LS
Metals used in manufacturing are usually alloys, which are composed
of two or more elements, at least one of which is a metallic element.
Metals and alloys can be divided into two basic groups:
(1) ferrous and
(2) nonferrous.
METALS

FERROUS
METALS
Ferrous metals are based on iron; the group includes steel and cast iron. These metals constitute the most
important group commercially, more than three-fourths of the metal tonnage throughout the world.

Steel is defined as an iron–carbon alloy containing 0.02% to 2.11% carbon. It is the most important category
within the ferrous metal group. Applications of steel include construction (bridges, I-beams, and nails),
transportation (trucks, rails, and rolling stock for railroads), and consumer products (automobiles and
appliances).

Cast iron is an alloy of iron and carbon (2% to 4%) used in casting (primarily sand casting); silicon is also
present in the alloy (in amounts from 0.5% to 3%). Cast iron is available in several different forms, of which
gray cast iron is the most common; its applications include blocks and heads for internal combustion engines.
METALS

Steel Cast Iron

METALS

NONFERROUS
METALS
Nonferrous metals include the other metallic elements and their
alloys. In almost all cases, the alloys are more important
commercially than the pure metals. The nonferrous metals include
the pure metals and alloys of aluminum, copper, gold, magnesium,
nickel, silver, tin, titanium, zinc, and other metals.
METALS

NONFERROUS
METALS
 CERAMIC
S
A ceramic is a compound containing metallic (or semimetallic)
and nonmetallic elements. Typical nonmetallic elements are
oxygen, nitrogen, and carbon. Ceramics include a variety of
traditional and modern materials.
CERAMI
C

Traditional ceramics include clay, consisting of fine particles of hydrous

aluminum silicates and other minerals used in making brick, tile, and pottery;
silica, the basis for nearly all glass products; and alumina and silicon carbide,
two abrasive materials used in grinding.

Newer ceramics include carbides, metal carbides such as tungsten carbide

and titanium carbide, which are widely used as cutting tool materials; and
nitrides, metal and semimetal nitrides such as titanium nitride and boron
nitride, used as cutting tools and grinding abrasives.
CERAMI
C

For processing purposes, ceramics can be divided into crystalline ceramics and
glasses. Different manufacturing methods are required for the two types.

Crystalline ceramics are formed in various ways from powders and then heated
to a temperature below the melting point to achieve bonding between the
powders.

The Glass ceramics (namely, glass) can be melted and cast, and then formed in
processes such as traditional glass blowing.
CERAMI
C

CERAMIC
PRODUCTS
 POLYMER
S
A polymer is a compound formed of repeating structural units called
mers, whose atoms share electrons to form very large molecules.
Polymers usually consist of carbon plus one or more other elements such
as hydrogen, nitrogen, oxygen, and chlorine.
Polymers are divided into three categories:
(1) thermoplastic polymers,
(2) thermosetting polymers, and
(3) elastomers.
POLYME
R

Thermoplastic polymers can be subjected to multiple heating and cooling

cycles without substantially altering the molecular structure of the polymer.
Common thermoplastics include polyethylene, polypropylene, polystyrene,
polyvinylchloride, and nylon.
POLYME
R

Thermosetting polymers chemically transform (cure) into a rigid structure

upon cooling from a heated plastic condition, hence the name thermosetting.
Members of this type include phenolics, amino resins, and epoxies.
POLYME
R

Elastomers are polymers that exhibit significant elastic behavior. They

include natural rubber, neoprene, silicone, and polyurethane.
 COMPOSITE
Smixtures of the other three types.
Composites are

A composite is a material consisting of two or more phases that

are processed separately and then bonded together to achieve
properties superior to those of its constituents.
COMPOSIT
E

Properties of a composite depend on its components, the physical shapes of the

components, and the way they are combined to form the final material.

Some composites combine high strength with light weight and are suited to
applications such as aircraft components, car bodies, boat hulls, tennis rackets,
and fishing rods.

Other composites are strong, hard, and capable of maintaining these properties
at elevated temperatures, for example, cemented carbide cutting tools.
COMPOSIT
E

COMPOSITE
S
 PART 3

MANUFACTURING PROCESSES
A manufacturing process is a designed procedure that results in physical and/or chemical
changes to a starting work material with the intention of increasing the value of that
material. A manufacturing process is usually carried out as a unit operation, which means it
is a single step in the sequence of steps required to transform a starting material into a final
part or product.

Manufacturing operations can be divided into two basic types:

(1) processing operations and
(2) assembly operations.
Manufacturing Process

Classification of Manufacturing Processes

 PROCESSING
OPERATIONS
A processing operation uses energy to alter a work part’s shape, physical
properties, or appearance to add value to the material. The forms of energy
include mechanical, thermal, electrical, and chemical. The energy is applied
in a controlled way by means of machinery and tooling.
Processing Operations

Three categories of processing operations are distinguished:

(1) shaping operations,
(2) property enhancing operations, and
(3) surface processing operations.

Shaping operations alter the geometry of the starting work material by various
methods. Common shaping processes include casting, forging, and machining.

Property-enhancing operations improve its physical properties without changing

its shape; heat treatment is the most common example.

Surface processing operations are performed to clean, treat, coat, or deposit

material onto the exterior surface of the work. Common examples of coating are
plating and painting.
Processing Operations

SHAPING
PROCESSES
Most shape processing operations apply heat, mechanical force, or a
combination of these to effect a change in geometry of the work material.

There are four categories of shaping processes:

(1) solidification processes,
(2) particulate processing,
(3) deformation processes, and
(4) material removal processes.
Processing Operations

In solidification processes, the starting material is a heated liquid or semifluid that

cools and solidifies to form the part geometry;

Casting and molding processes

start with a work material heated to
a fluid or semifluid state.

The process consists of:

(1) pouring the fluid into a mold
cavity and
(2) allowing the fluid to solidify,
after which the solid part is
removed from the mold.
Processing Operations

In particulate processing, the starting material is a powder, and the powders are formed
and heated into the desired geometry;

Particulate processing:
(1) the starting material is powder; the
usual process consists of
(2) pressing and
(3) sintering.
Processing Operations

In deformation processes, he starting material is a ductile solid (commonly metal) that is

deformed to shape the part.

Some common deformation processes:

(a) forging, inwhich two halves of a
die squeeze the work part,
causing it to assume the shape of the
die cavity;

(b) extrusion, in which a billet is

forced to flow through a die orifice,
thus taking the cross-sectional shape of
the orifice.
Processing Operations

In material removal processes, the starting material is a solid (ductile or brittle), from which
material is removed so that the resulting part has the desired geometry.

Common machining operations: (a) turning, in which a single-point cutting tool removes metal from a rotating
workpiece to reduce its diameter; (b) drilling, in which a rotating drill bit is fed into the work to create a round hole;
and (c) milling, in which a work part is fed past a rotating cutter with multiple cutting teeth.
Processing Operations

PROPERTY-ENHANCING
PROCESSES
Property-enhancing process is performed to improve mechanical or physical
properties of the work material. These processes do not alter the shape of the
part.

The most important property-enhancing processes involve heat treatments,

which include various annealing and strengthening processes for metals and
glasses.

Sintering of powdered metals is also a heat treatment that strengthens a pressed

powder metal work part. Its counterpart in ceramics is called firing.
Processing Operations

SURFACE PROCESSING
Surface processing operations include (1) cleaning, (2) surface treatments, and (3) coating and
thin film deposition processes.

Cleaning includes both chemical and mechanical processes to remove dirt, oil, and other
contaminants from the surface.

Surface treatments include mechanical working such as shot peening and sand blasting, and
physical processes such as diffusion and ion implantation.

Coating and thin film deposition processes apply a coating of material to the exterior surface
of the work part.
 ASSEMBLY OPERATIONS
In Assembly Operations, two or more separate parts are joined to form a
new entity. Components of the new entity are connected either permanently
or semipermanently.

Permanent joining processes include welding, brazing, soldering, and

adhesive bonding. They form a joint between components that cannot be
easily disconnected.

Mechanical assembly methods are available to fasten together two (or

more) parts in a joint that can be conveniently disassembled. Example are
use of screws, bolts, and other threaded fasteners.
 PRODUCTION
EQUIPMENT
Production equipment can be general purpose or special purpose.

General purpose equipment is more flexible and adaptable to a variety of

jobs. It is commercially available for any manufacturing company to invest
in.

Special purpose equipment is usually designed to produce a specific part or

product in very large quantities.
Production Equipment

Process Equipment Special Tooling /Function

Molding Molding machine Mold (cavity for hot polymer)
Rolling Rolling mill Roll (reduce work thickness)
Forging Forge hammer or press Die (squeeze work to shape)
Extrusion Press Extrusion die (reduce cross section)
Stamping Press Die (shearing, forming sheet metal)
Machining Machine tool Cutting tool (material removal)
Fixture (hold work part)
Jig (hold part and guide tool)
Grinding Grinding machine Grinding wheel (material removal)
Welding Welding machine Electrode (fusion of work metal)
 PART 4

PRODUCTION SYSTEM
 PRODUCTION SYSTEM
To operate effectively, a manufacturing firm must have systems that allow it to efficiently
accomplish its type of production.
Production systems consist of people, equipment, and procedures designed for the combination
of materials and processes that constitute a firm’s manufacturing operations.

Production systems can be divided into two categories:

(1) production facilities and
(2) manufacturing support systems
MODEL OF PRODUCTION SYSTEM
 PRODUCTION
FACILITIES
Production facilities consist of the factory and the production, material
handling, and other equipment in the factory.

The equipment comes in direct physical contact with the parts and/or
assemblies as they are being made. The facilities “touch” the product.

Facilities also include the way the equipment is arranged in the factory,
called the plant layout.
MANUFACTURING SUPPORT
SYSTEMS
To operate its facilities efficiently, a company must organize itself to design
the processes and equipment, plan and control the production orders, and
satisfy product quality requirements.

These functions are accomplished by manufacturing support systems—people

and procedures by which a company manages its production operations.

Most of these support systems do not directly contact the product, but they
plan and control its progress through the factory.
Manufacturing Support System

Manufacturing support functions are often carried out in the firm by people organized into
departments such as the following:

⮚ Manufacturing engineering - responsible for planning the manufacturing processes, deciding

what processes should be used to make the parts and assemble the products. This department is
also involved in designing and ordering the machine tools and other equipment used by the
operating departments to accomplish processing and assembly.

⮚ Production planning and control - responsible for solving the logistics problem in
manufacturing, ordering materials and purchased parts, scheduling production, and making sure
that the operating departments have the necessary capacity to meet the production schedules.

⮚ Quality control - should be a top priority of any manufacturing firm in today’s competitive
environment. It means designing and building products that conform to specifications and satisfy
or exceed customer expectations.
Reference/s:

Fundamentals of Modern Manufacturing – Seventh Edition by Mikell P. Groover